S.

Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7. Sub Assembly of Outside
gears in counter Circlip plier
shaft
 Assemble 1st circlip.

 Assemble3rd& 4 thsliding NOTE:

gear on the shaft such
that the larger gear is Larger gear
facing the 5th gear. must be
towards the
1st gear.

 Assemble 2nd circlip. Outside

Circlip plier

 Assemble2ndgear.
NOTE:
Collar in the
gear should
face towards
1stgear.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
8. Counter shaft NOTE:
thrust washer
Apply grease on thrust
 Place thrust washer over washer to preventit from
counter shaft bearing in falling off when locating
CrankcaseLH. main shaft.

9. Counter shaft &

NOTE:
Drive shaft in
Ensure threaded end of
Crankcase LH counter shaft is facing
 Locate the shafts in their upwards & threaded end of
respective locations in main shaft is inserted into
CrankcaseLH, ensuring Crankcase LH.
the gears in both shafts Gently tap both shafts into
are aligned. bearings simultaneously
for proper seating.

10. Sub Assembly of

gears in Drive shaft
 Assemble5 thgear such
that the gear side is
facing towards 1stgear.

 Assemble thrust washer.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
10. Sub Assembly of
gears in Drive shaft
 Assemble1stgear bush.

 Assemble 1st gear over

the bush such that the
deep groove in 5th gear is
facing towards 1st gear.

 Assemble thrust washer

NOTE:
over 1st gear
Ensure gears in both
counter shaft & drive shaft
are aligned.

11 Selector Forks
 Locate selector fork
No.2, inside sliding dog
of on drive shaft, with
thefork lug facing
above.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
11. Selector Forks
 Locate operator fork
No1 in the recess in drive
shaft 5th gear.

 Locate operator fork

No.3 in counter shaft on
4th gear.

12. Gear Shift Drum

Assembly
 Insert long end of Shift
Drum Assembly into
Crankcase LH. (thetwo
offset pegs in the drum
assy must be facing
outside.)

 Lock selector forks in

position by locating the
spindles in Crankcase
LH.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
13. Crank shaft NOTE:
Assembly
Smear oil on bearing outer
 Locate bearing in the race.
housing in Crankcase LH
Hold crankshaft vertically
and press crankshaft
& ensure bearing enters
gently till the bearing is
crankcase LH squarely.
seated completely.
 Rotate Crankshaft such
that the crank webs are
at their lowest position &
the dot mark on the gear
in crankshaft is facing
towards the front.

14. Balancer shaft NOTE:

Assembly
Ensure dot marks on
 Position balancer shaft crankshaft gear & balancer
such that the dot mark shaft gear are matched
on balancer shaft gear correctly.
aligns with dot mark on
crankshaft gear and
gently press balancer
shaft into the bearing in
crankcase LH

15. Crankcase Boxing NOTE:

 Ensure Gasket sealant is Apply Loctite No 5699 on
applied evenly and the mating surface of crank
uniformly on the mating case LH.
surface of crankcase LH
 Ensure dowels are
located in crankcase LH.
 Locate Crankcase RH
over crankcase LH and
gently tap it in while
gently rotating the
shafts
 Ensure Crankcase RH is
fully seated over crank-
case LH & all shafts are
rotating freely.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
16. Crankcase Hex Socket Hd Screw:
Fasteners M8 X 100
Assemble Allen key: M6
Torque: 2-2.4KgM (20-
 Hex Socket Head screw 24Nm)
in Crankcase LH below
Barrel seating area.

 3 hex bolts in magneto Hex Flange Bolt- M8 X 70

area in crankcase LH. Socket spanner: 12mm
Torque: 2-2.4KgM (20-
24Nm)

 1 Hex flange bolt in Hex Flange Bolt- M6 X

crankcase LH near 60 Socket spanner: 8mm
starter motor housing Torque: 0.8-1.2KgM (8-
12Nm)

 4 Hex flange bolts in

Hex Flange Bolt- M6 X
crankcase LHfront.
60 Socket spanner: 8mm
Torque: 0.8-1.2KgM (8-
12Nm)

 6 Hex bolts (Longest) in

Hex Flange Bolt- M6 X 85
crankcase LHrear.
Socket spanner: 8mm
Torque: 0.8-1.2KgM (8-
12Nm)

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
16. Crankcase
Hex Flange Bolt- M6 X 60
Fasteners Socket spanner: 8mm
Assemble Torque: 0.8-1.2KgM (8-
12Nm)
 3 Hex bolts from crank-
case LH bottom NOTE:
Tighten all fasteners evenly &
diagonally, for proper sealing
of the crankcase joints

17. Piston Rings NOTE:

Assembly
 Assemble Oil control ring
with stiffener ring in the
3rd groove.
Ensure stiffener ring is
correctly located between
the 2 oil Control rings.

 Assemble 2nd compression

ring in the middle
groove.
 Assemble 1st compression
ring in the top most
groove.
NOTE:
Ensure the words “TOP” 2
in 2nd compression ring &
“TOP 1” in 1st compression
ring are facing towards the
top of the piston.
Lubricate rings well &
position ring end gaps at
120o to each other, for easy
assembly of cylinder barrel.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
18. Oil Jet
NOTE:
 Locate oil jet in Crank-
Ensure ‘O’ ring does not get
case RH, barrel seating
damaged during assembly.
area with its slotted end
facing up and press into Ensure slotted end of jet is
crank-case gently. facing outside.

19. Cylinder Barrel NOTE:

Gasket
 Locate the two dowels
on Crankcase LH.
 Locate gasket on Crank-
case ensuring the recess
for the oil jet is correctly
positioned.
Apply grease on gasket
seating surface.
Caution:
Gasket is unidirectional
hence ensure it is fitted
correctly.

20. Piston Assembly on CAUTION:

Connecting Rod
Ensure circlip locks in place
 Assemble circlip on and does not fall into
piston, on one side & crankcase.
insert piston pin from
Remove cloth after
the other side. Ensure
assembling circlip.
the pin is pressed just
sufficiently into the
piston and not
protruding into piston

 Support connecting rod Special Tool: ST-27529-2,

using special tool to Piston Support.
hold it vertically for
assembling piston.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
20. Piston Assembly on
NOTE:
Connecting Rod
Ensure marking, “EX” on the
 Position piston on
piston is facing towards
connecting rod, ensuring
the piston pin holes in crankcase front.
both piston & connecting
rod are aligned. CAUTION:
 Lubricate piston pin &
gently insert into piston Ensure circlip locks in place
till it rests on the circlip and does not fall into
crankcase.
 Cover crankcase spigot
suitably & assemble the Remove cloth after assembl-
other circlip on the ing circlip.
piston.

21. Cylinder Barrel on

piston
 Lubricate piston rings,
piston & cylinder barrel,
with oil, for easy entry of
piston into cylinder
barrel.
 Ensure Piston is
supported vertically.
 Gently lower barrel
over piston while
simultaneously
compressing rings for
easy entry.

 Remove piston support-

ing tool & lower barrel
fully into Crankcase.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
21. Cylinder Barrel on
Hex Flange Nut: M6 X 1
piston D E Spanner: 8 mm
 Rotate Crank Shaft Torque: 0.8-1.2KgM (8-
Assembly to bring 12Nm)
piston to TDC.

 Tighten barrel to
Crankcase using 2
Flanged Hex nuts on the
LH side.

22. Cylinder head NOTE:

Gasket
Apply grease on cylinder
 Locate 2 dowels on head gasket for proper
cylinder barrel top LH seating.
side.· Locate cylinder
head gasket over the
cylinder barrel.

23. Cam Chain Pads

Stepped Hex socket
 Insert chain tensioner
pad through cylinder Bolt: M6X14
barrel. Allen Key: M5
 Apply grease on the Torque: 1.0 - 1.2KgM (10-
thrust washer to hold it 12Nm)
in place over the threaded
location in crankcase LH.
 Position chain pad over
thrust washer & tighten
with hex socket Head
stepped bolt.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
23. Cam Chain Pads
NOTE:
 Insert the cam chain
Apply grease on the gear &
through the cylinder
chain to hold the chain in
barrel & locate it on the
place.
crank shaft gear.

 Ensure chain is properly

supported at the top to
prevent it from dropping
into the crankcase.

 Insert fixed cam chain

pad through cylinder
barrel & locate it in the
crankcase LH
NOTE:
Ensure fixed chain pad is
locked in position in cylinder
barrel.as well as crankcase
LH.

24. Valves in Cylinder NOTE:

Head
Ensure stem seals are fitted
 Insert inlet valve into on the valve guide.
valve guide from inside
cylinder head. Ensure denser coils of the
 Assemble spring seat, spring are seated on the
inner spring, outer spring seat in cylinder head.
spring &retainer, from
the top of cylinder head.
 Locate valve spring
compressing tool over
the retainer & compress
spring till the valve stem
comes out through the
retainer.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
24. Valves in Cylinder
Special tool: ST-27528-2,
head. Valve spring compressor.
 Insert split collars on
retainer. Ensure they are
seated correctly against
valve stem and retainer
& release puller slowly.

 Repeat above procedure CAUTION:

to assemble exhaust
valve. Ensuresplit collars are
correctly locked between
retainer & valve stem.

25. Cylinder Head NOTE:

Assembly
Apply grease on crankshaft
 Position cylinder head sprocket & chain to hold it
assembly over cylinder in place.
barrel.
Secure chain from top to
 Holding the cam chain prevent it from dropping
from the top, route it into crankcase.
through the slot in
cylinder head bottom
and locate the cylinder
head on the barrel
correctly.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
25. Cylinder Head
Special Hex Bolts:M10X170
Assembly Hex Socket: 12mm
 Locate 4 special Hex Torque: 4-4.5KgM (40-
bolts with washer & 45Nm)
tighten diagonally.

 Locate 2 Hex flange bolts Hex flange bolts: M6X30

on cylinder head LHside D E Spanner: 8mm
and tighten. Torque: 0.8-1.2KgM(8-
12Nm)

26. Cam Chain & NOTE:

Sprocket Assembly
 Locate cam shaft along
with sprocket on cylinder
head.
Ensure Key way in crankshaft
is facing up so that piston is at
TDC on compression stroke.

 Ensure sprocket is free

on cam shaft & locate CAUTION:
chain on sprocket with
marking “T” on sprocket - Ensure reference lines on
facing up. cam sprocket & cam
 Rotate cam shaft, shaft are parallel &
without disturbing the aligned.
sprocket till the dowel in
the shaft aligns with the - Crankshaft keyway is at
hole in the sprocket. TDC position.
 Ensure chain has no
slack & Insert cam shaft
into sprocket such that
the dowel locates into
the sprocket.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
26. Cam Chain &
Sprocket Assembly
 Fix 1 hex bolt with lock
plate on sprocket &
tighten just sufficiently.
 Rotate camshaft slowly
& tighten 2nd Hex bolt,
through the lock plate.

 Tighten both bolts & Hex Bolt: M6X12

bend lock plate over the Hex Socket: 8 mm
bolts. Torque: 1-1.2KgM (10-
12Nm)

27. Cam Shaft Lock NOTE:

“C”washer.
Ensure “C” washer is located
 Align slot in cam shaft correctly into the slot in
with the groove in cylinder head failing which
cylinder head. the cylinder head cover
cannot seat properly
 Insert “C” washer into
cylinder head to lock
axial movement of the
cam shaft

28. Auto Chain Tensioner NOTE:

Assembly
Ensure gasket is assembled
 Ensure center bolt with on the Auto chain tensioner
spring is removed from Assembly.
assembly.
 Release lock on chain
tensioner body &
depress pad completely.

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No. Instructions
28. Auto Chain Tensioner
Assembly
 Locate chain tensioner
assembly in cylinder
barrel& tighten with 2
Hex socket head screws.
 Locate ‘O’ ring in the
chain tensioner body.
 Insert spring into chain
tensioner and tighten
with special Hex bolt.
29. Spark Plug
 Assemble spark plug on
cylinder head.
30. Inlet Manifold
 Assemble Inlet manifold
with the PAV inlet nipple
facing downwards.
 Tighten with 2 Hex
socket head screws with
copper washers.
94 ROYAL ENFIELD SERVICE MANUAL LS 410
Fastener, Size, Tool Usage, Precautions, Photos
NOTE:
Ensure lock in chain
tensioner assembly is facing
downwards
Hex Socket Hd Screw:
M6X25
Allen Key: 5mm
Torque: 1-1.2KgM (10-
12Nm)
Special Hex bolt: M8
Hex socket: 10mm
Torque: 0.8-1.0KgM (8-
10Nm)
NOTE:
Ensurespark plug gap is set
0.7 - 0.8 mm
Socket Spanner: 16mm
Torque: 1-1.5KgM (10-
15Nm)
NOTE:
Ensure ‘O’ ring is located in
the Inlet manifold.
Hex Socket Hd screw:
M6X25
Allen key: 5mm
Torque: 0.8-1.2KgM (8-
12Nm)
 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
31. Inlet Rocker arm &
shaft in Cylinder
head cover
 Position inlet rocker arm
inside cover such that
the tappet adjustment
screw on the rocker arm
is facing outside &roller is
facing inside.

 Assemble rocker shaft in

the cylinder head cover
such that the slot and
the internal threads in
the shaft are facing
outside.

 Ensure the slot in the

rocker shaft is per-
pendicular to the top
mounting hole in the
cylinder head cover such
that the cover mounting
bolt can pass through
the slot in the rocker
shaft.

32. Exhaust Rocker arm

& shaft in Cylinder
head cover
· Positionexhaust rocker
arm inside cover such
that the tappet adjust-
ment screw on the
rocker arm is facing
outside &roller is facing
inside.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
32 Exhaust Rocker arm
& shaft in Cylinder
head cover
 Assemble rocker shaft in
the cylinder head cover
such that the slot and
the internal threads in
the shaft are facing
outside.

 Ensure the slot in the

rocker shaft is
perpendicular to the top
mounting hole in the
cylinder head cover such
that the cover mounting
bolt can pass through
the slot in the rocker
shaft.
 Assemble 2 Hex Socket Hex Socket Hd plug:
pre coated plugs with M14X12
copper washers in the Allen key: 8mm
cylinder head cover. Torque: 2.5-3.0KgM (25-
30Nm)

33. Cylinder Head NOTE:

Cover
- Ensure the 2 dowels are
 Apply Loctite 5900 located in cylinder head.
gasket sealant on cylinder
head mating surface. - Aluminum washers are
 Locate cylinder head provided to prevent oil
cover on the cylinder head leak through the bolts.
and ensure proper seating.
 Assemble 2 long Hex
flange bolts with
aluminum washers in
the top RH side.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
33. Cylinder Head
Hex flange bolts: M6X55
Cover Socket Spanner: 8mm
 Assemble 3 long Hex
flange bolts in the top RH Hex flange bolts: M6X60
side.· Assemble 2 long Socket Spanner: 8mm
Hex flange bolts with
aluminium washers in
NOTE:
the centre RH side.
Aluminium washers are
 Assemble 3 long Hex provided to prevent oil leak
flange bolts in the top LH through the bolts.
side.
Hex flange bolts: M6X60
 Assemble medium
Socket Spanner: 8mm
length Hex flange bolt in
the RH side rear.
Hex flange bolts: M6X45
 Assemble small Hex Socket Spanner: 8mm
flange bolt in RH side
front. Hex flange bolts: M6X40
Socket Spanner: 8mm
 Assemble 2 fully
threaded Hex flange
bolts inside the inlet & Hex flange bolts: M6X21
Exhaust tappet housing Socket Spanner: 8mm
areas.

 Tighten all the bol ts

just sufficiently. Do not
torque tighten fully

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No. Instructions
34. Camshaft Cover
small.
 Locate ‘O’ ring in cam
shaft cover small.
 Locate cam shaft cover
in cylinder head & align
fixing hole.
 Assemble Hex flange
bolt (fully threaded).
 Tighten Hex flange bolt
on cam shaft cover
small AND the 12 bolts
on cylinder head cover,
diagonally using 8mm
socket span ner to
respective torque values.
Fastener, Size, Tool Usage, Precautions, Photos
NOTE:
Apply Loctite 5900 gasket
sealant on seating face
before locating on cylinder
head cover
Hex flange bolt: M6X16
Socket spanner: 8mm
Hex flange bolts: M6X60,
M6X55, M6X45& M6X40
Torque: 1.0-1.4KgM (10-
14Nm)
Hex flange bolts:M6X21
Torque: 0.8-1.2KgM (8-
12Nm)

35. Cam Shaft Cover Hex flange bolt: M6X16

Big
 Assemble cover and
tighten with 2 Hex flange
bolts (fully threaded)
Socket spanner: 8mm
Torque: 0.8-1.2KgM (8-
12Nm)

36. Tappets Adjustment NOTE:

 I f Magneto rotorNOT
fitted on crankshaft: Tappets MUST be adjusted
- Ensure key way on ONLY WHEN:
crankshaft is facing up &
piston is at TDC - Engine is cold
 If Magneto rotor is fitted
on crankshaft - Piston is at TDC on
- Rotate magneto rotor Compression stroke.
“CLOCKWISE ONLY”such
that the reference mark on
the rotor aligns with the
inspection hole on cover LH/
Reference mark on
Crankcase LH.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
36. Tappets
Special Tool: ST-27527-2,
Adjustment Tappet adjusting tool &
 Locate special tool & pointed, long feeler strip.
loosen adjuster lock nut
by turning the long lever
anticlockwise. Tappet Setting:
 Using a pointed feeler Inlet: 0.08 - 0.10mm
strip, set the specified Exhaust: 0.23 - 0.25mm
gap by rotating the
knurled head of the
special tool: CAUTION:
- Clockwise to reduce DO NOT adjust the tappets
gap.
too tight as it will result in
- An ticlockwise to heavy load coming on the
increase gap.
rocker shafts and damaging
 Hold the knurled head
firmly so that the tappet the bore in the cylinder head
adjustment does not get cover.
gets disturbed & lock the
tappet locknut firmly by
turning long lever clock-
wise.

37. Tappet Adjuster Hex flange bolts: M6X21

Cover Inlet Socket Spanner: 8mm
Torque: 0.8-1.2KgM (8-12
 Locate O Ring in cover
inlet & position cover
over cylinder head
cover.· Ti gh t e n
with 2 Hex bolts.

38. Tappet Adjuster Hex flange bolts: M6X21

Cover Exhaust Socket Spanner: 8mm
Torque: 0.8-1.2KgM (8-12
 Locate O Ring in cover
Nm)
exhaust & position
cover over cylinder head
cover.
 Tighten with 2 hex bolts.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
39. Starter Clutch
CAUTION:
Assembly
Do not force or hammer
 Assemble starter clutch
starter bearing into ring gear
such that the starter
as it will damage the starter
shoulder is seated in the
bearing.
groove in the ring
bearing. Apply oil & gently press the
bearing into the ring gear.

 Locate ring gear with

starter clutch on
magneto such that the
recess in the ring bearing
is seated on the
magneto.

 Tighten ring gear to Hex SocHd screw: M6X20

magneto with 6 Hex Allen key: M5
Socket Head screws. Torque: 1.0-1.2KgM (10-12
Nm)

 Assemble Big ring gear

into starter clutch by
rotating anti clock wise &
pressing gently, to allow
for starter clutch to
expand and allow flush
seating of big ring gear

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
40. Magneto rotor
 Ensure the crankshaft is
in TDC position and
locate woodruff key on
shaft.

 Locate Magneto rotor

with starter clutch on
the shaft ensuring the
woodruff key slot is
correctly aligned with
the woodruff key and
gently tap magneto
rotor till it is seated fully
in the shaft Hex nut: M12X1.25X11
 Locate rotor holding Socket spanner: 19mm
special tool in the Torque: 7-8KgM (70-80
magneto rotor Nm)
 Ensure the 3 lugs of the
special tool are firmly Special Tool: ST-27534-2,
seated on 3 hex socket Magneto rotor & FD
head screws inside sprocket locking tool
magneto rotor to
prevent it from rotating
while tightening.
 Assemble Hex Flange
nut and tighten.
 Remove the magneto
rotor holding special tool

41. Idler gears on

Crankcase LH
 Insert the 2 idler gear
spindles into crankcase
LH
 Assemble double gear
with the smaller gear
facing outwards.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
41. Idler gears on
Crankcase LH
 Assemble spacer bush.

 Assemble idler gear.

 Assemble spacer bush.

42. Starter Motor

NOTE:
 Insert starter motor into
Ensure wire terminal of
LH case spigot ensuring
starter motor is facing
correct engagement of
upwards.
starter motor shaft with
double gear.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
42. Starter Motor
NOTE:
 Tighten starter motor to Ensure earth terminal is
crankcase with 2 hex located on the outside hex
flange bolts. flange bolt of the starter
motor before tightening
both bolts.
Hex flange bolt: M8
Socket Spanner: 10mm
Torque:0.8-1.2KgM (10-12Nm)

43. Drive Shaft Spacer

 Fix ‘O’ ring inside the
spacer.

 Assemble spacer on
NOTE:
drive shaft.
The spacer has to be
assembled on the shaft such
that the 4 slots are facing
inside.

44. FD Sprocket
 Assemble FD sprocket
on drive shaft.

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Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
44. FD Sprocket
Special Tool: ST-27534-2,
 Assemble lock washer. Magneto rotor & FD
sprocket locking tool

 Tighten Hex nut to Hex U nut: M27

torque& lock tab washer Socket spanner: 32mm
over Hex nut by bending Torque: 13-16KgM (130-
at opposite ends. 160Nm)

45. Gear Position NOTE:

Indicator
 Locate switch on
crankcase LH ensuring
the offset holes match
with the threads in
crankcase LH.
 Tighten with 2 Hex
flange bolts.
Ensure ‘O’ ring is located
properly on the gear
position indicator switch.
Hex flange bolt: M6
Socket spanner: 8mm
Torque: 0.8-1.2KgM (8-
12Nm)

46. Cover LH
 Ensure dowel is located
on Crankcase LH.

104 ROYAL ENFIELD SERVICE MANUAL LS 410